30/05/2024 08:30:01
Door Assembly - Front - LH (Remove and Replace)
Correction Code 10106002
- 2023-11-21: Added rework instructions to enable fitting of early type pressure sensor to new type door.
- 2023-08-22: Revised procedure using the latest vehicle validation.
Removal
- Open the LH front door and lower the window.
- Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
-
Latch the LH front door to allow
the window to fully raise.
NoteDo not close the door with the window in this position, as upper bright trim will be damaged.
-
Apply masking tape to the LH
front door handle grip to prevent damage to the chrome surface of the grip.
- Remove the LH front door panel. See Panel - Door Trim - Front - LH (Remove and Install).
-
Remove the LH front window outer
belt seal.
NoteLift and roll outward slowly and evenly starting from the rear edge. Be careful not to bend or damage components.
-
Remove the LH front inner belt
seal from the upper door assembly.
NoteTake care not to bend the inner belt seal during removal.
-
Connect the window switch tool to
the vehicle.
-
Fully raise the LH front
window.
-
Remove butyl patch and door
tape.
-
Disconnect the door harness
connector to LH front door speaker.
-
Remove the screws (x4) that
attach the LH front door speaker to the spacer ring.
-
Remove the screws (x4) that
attach the speaker spacer ring to the door shell.
-
Loosen the nut that attaches the
LH front window glass to the window regulator.
-
Roll window up or down so that
the regulator clip is visible, depress the clip and lift on glass to remove from
the regulator clip and door body.
NotePlace door glass in a safe area while working on the vehicle to prevent damage.
-
Remove the upper door clips (x4)
from the door assembly.
-
Disconnect the window switch tool
from the LH front door harness.
- Disconnect 12V power. See Disconnect 12V Power.
-
Disconnect the exterior door
mirror connectors (x2).
-
Remove the clip on the door flap
seal to gain access to the exterior mirror assembly bolts.
-
Remove the bolts (x3) of the
exterior mirror assembly.
-
Remove the foam seal from the
exterior mirror assembly.
- Remove the exterior mirror assembly from the vehicle.
-
Remove the pressure sensor from
the door:
- Vehicles built before February 11, 2019: Remove the screws (x2) that attach the pressure sensor to the door (torque 5 Nm), and then disconnect the sensor harness.
- Vehicles built after February 11, 2019: Depress the locking tab on the pressure sensor, and then pull the connector away from the sensor. Rotate the pressure sensor clockwise 90 degrees to remove the pressure sensor from the door.
-
Disconnect the door harness
connector to the door handle controller.
-
Disconnect the door harness
connectors (x3) to the door control unit.
-
Remove the LH front door closeout
panel.
Note6x bolts, T25, 4 Nm. 1x clip to door wiring harness
-
Remove the plugs (x2) that covers
the LH front window regulator lower nuts.
-
Remove the lower nuts (x2) from
the LH front window regulator
-
Remove the upper nuts (x2) from
the LH front window regulator.
-
Remove the screws (x3) that
attach the regulator motor to the door.
-
Disconnect the harness connector
and remove the LH front window regulator from the door assembly.
NotePivot the LH front window regulator counterclockwise and release it through the closeout opening in the door assembly.
-
Disconnect the 3.0 door handle
harness from the LH front door handle assembly.
-
Remove the nuts (x4) that attach
the LH front door handle to the door.
-
Remove the LH front door handle
through the access opening.
-
Remove the bolts (x2) that attach
the latch to the door assembly.
-
Remove the door latch from the
door assembly.
Note1x connector. Carefully release the latch assembly from the door outer panel, and then disconnect the latch harness connector.
-
Release the clips that attach the
LH front door harness to the door assembly.
Note12x clips, 1x rubber grommet
-
Remove the LH front door seal
from the door assembly.
Note22x clips.
-
Remove the LH front door harness
from the door assembly.
Note1x grommet.
-
Remove the bolts (x4) that attach
the LH front door assembly to the hinges, remove the door from the vehicle and put
it on a padded surface.
NoteAssistance is recommended.
Installation
CAUTION
If using this procedure to
install an unpainted part, make sure to apply seam sealer to all seams prior to
installing and painting the part. Refer to the Collision Repair manual for more
information.
Note
When replacing an old type door (vehicles built before
February 11, 2019) with a new one, the door needs to be reworked to enable fitting of
the old pressure sensor to the new door. For details, see TN-19-10-001 - Rework Front Door Panel For Earlier Pressure
Sensor Design .
Note
If the door needs to be reworked, add correction code
10106007 (LH door) or 10106107 (RH door) as a separate activity to the Service
Visit.
-
Install the bolts (x4) that
attach the LH front door assembly to the hinges on the vehicle (torque 31
Nm).
-
Insert the LH front door harness
into the door assembly and attach the grommet to the door assembly.
-
Install the LH front door seal
onto the door assembly.
Note22x clips.
-
Attach the LH front door harness
to the door assembly.
Note12x clips, 1x rubber grommet
-
Install the bolts (x2) that
attach the latch to the door assembly (torque 10 Nm).
-
Connect the door harness
connector to the latch assembly.
-
Install the nuts (x4) that attach
the door handle assembly to the LH front door, and then hand tighten the
nuts.
NoteLeave hardware loose enough so that door handle assembly can be moved for alignment
-
Align the door handle and torque
the nuts (x4) to 9 Nm.
-
Connect the 3.0 door handle
harness to the door handle assembly.
-
Adjust the LH front door handle
for flushness to the door.
Note1x adjustment screw, T40. Flush measurement of door handle should be adjusted to similar flush measurements of other handles on the vehicle.
-
Install the LH front window
regulator into the door assembly.
Note1x connector. Position LH front window regulator into the closeout opening in the door assembly and pivot it clockwise to put it into place.
-
Install the nuts (x4) that attach
the LH front window regulator to the door assembly (torque 10 Nm).
-
Install the access plugs (x2)
onto the door assembly.
-
Install the screws (x3) that
attach the regulator motor to the door assembly (torque 2.4 Nm).
-
Install the screws (x4) that
attach the spacer ring to the door shell (torque 1.8 Nm).
-
Install the screws (x4) that
attach the LH front door speaker to the spacer ring (torque 1.8 Nm).
-
Connect the door harness
connector to the LH front door speaker.
-
Install the upper door clips (x4)
onto the door assembly.
-
Inspect the mirror area of the
door assembly.
Note2x nylon shims. Make sure that both nylon shims are present. Replace if damaged or missing.
-
Install the bolts (x3) that
attach the exterior mirror to the door assembly (torque 18 Nm).
NoteMake sure that the wiring harness connector is inboard of the door. Failure to install the fasteners using the following sequence can result in NVH issues
-
Install the exterior mirror
foam.
-
Install the door seal flap
retaining clip.
-
Connect the mirror connectors
(x2).
-
Install the front door pressure
sensor:
- Vehicles built before February 11, 2019: Install the screws (x2) that attach the pressure sensor to the door (torque 5 Nm), and then reconnect the harness to the pressure sensor.
- Vehicles built after February 11, 2019: Rotate the pressure sensor counter clockwise 90 degrees to secure the pressure sensor to the door, and then reconnect the harness to the pressure sensor.
-
Install the screws (x6) that
attach the LH front door closeout panel to the door (torque 4 Nm).
NoteMake sure that the inner door handle manual release cable is routed properly.
-
Connect the door harness
connector to the door handle controller.
-
Connect the door harness
connectors (x3) to the door control unit.
- Connect 12V power. See Disconnect 12V Power.
-
Connect the window switch tool to
the vehicle.
-
Install the door glass and lower
the window.
NoteMake sure to slide the glass into the track mounted on the front quarter glass.
-
Install the LH front inner belt
seal.
- Close the LH front door.
-
Install the outer belt seal to
the LH front door.
NoteUse P-80 Emulsion lubricant to lube belt molding for easy installation and gap adjustment
-
Adjust the glass to within
specifications.
Note1x nut, 10mm, 7.5 Nm. Measure at the end of the door seal radius #1, right above the Tesla logo #3, and half way between 1 and 3.
- Open the LH front door.
-
Torque the nut that attaches the
regulator to the moving glass (torque 7.5 Nm).
-
Verify correct operation of the
LH front window.
NoteCycle the LH front window, and listen and look for contact between the regulator and the wiring harness during operation. Make sure that the door handle harness and connectors are clear of the path of the regulator and moving glass.
-
Install stickers over the holes
in the inner door.
Note5x stickers. Replace if damaged or missing.
-
Disconnect the window switch tool
from the LH front door harness.
-
Install the LH front A-pillar
margin seal onto the door assembly.
Note3x clips. Align the margin seal onto the LH front edge of the door assembly. Peel off adhesive backing and attach the seal onto the door assembly.
-
Install the LH front door panel
clips.
NoteInstall new clips (x9). Attach felt tape around the clips
-
Gently spread the upper door
clips (x5) with a screwdriver to ensure adequate holding force to the door
panel.
- Install the LH front door panel. See Panel - Door Trim - Front - LH (Remove and Install).
- Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).